Bituminous emulsion and process of preparing same



Patented Apr. .3, i945 T O F FE aaiacse props SION AND PROCESS OF rnmanme SAME Walter B. Buckley, Berkeley, and Edwin P. Bly, San Francisco, Calif., assignors to American Bitumuls Company, San Francisco, Calif., a

corporation of Delaware No Drawing. Application September 12, 1939, Serial N0. 294,504

'10 Claims. (or. 252-3115) This invention relates to the manufacture of emulsions and more particularly to bituminous emulsions and process of preparing the same.

The term bituminous emulsions" as used herein embraces emulsions of asphalt, wax, pitch, tar,

oil and other similar hydrocarbon or organic products which are normally solid, semi-solid or highly viscous. The viscous or tacky nature of these materials makes difiicult direct application as binders, impregnants or superficial coatings .while in a continuous liquid phase. These diniculties have led to the use of emulsions for such purposes. Water is generally adopted as the-vehicle and is usually the continuous phase of the emulsion which surrounds the individual dis- -ful as roofing materials, in the construction of are encountered in the summer for relatively long periods.

A further object of the invention is to produce a bituminous emulsion which will retain its ability to mix with foreign materials and be free from coagulaton or breakdown during repeated cycles'of freem'ng and thawing and which can therefdre-bejsatisfactorily stored in cold regions during the winter.

A further object of the invention is to produce an emulsion which upon drying after application as a coating will give a bright, shiny, tacky surface in which the dispersed bituminous particles actually coalesce to form a substantially continuautomobiles, as liners for shoes and for many other purposes. Whenmixed with mineral-aggregates, bituminous emulsions have found particular utility in the pavement of highways, sidewalks, tennis courts and the like. More recently, the practical utility'of particular types of bituminous emulsions for soil stabilization has been established. .The oil-in-water type emulsions of the present invention are capable of all of the above applications and are adaptable for use wherever bituminous emulsions have heretofore been utilized.

Water-in-oil type emulsions, despite their high viscosity, are frequently applied in the coating of certain types of aggregates such as hydrophilic aggregates where satisfactory wetting or adhesion is not obtainable with the oil-in-water type of emulsion. Within the broader scope of this invention, such water-in-oil type emulsions stabilized with the novel stabilizers hereinafter described may be prepared. Such emulsionsare particularly adaptable for coating of hydrophilic aggregates as well as for other specialized uses.

It is an object of this invention to produce a bituminous emulsion which will'remain stable, usable and free from objectionable properties one phase.

An additional and important purpose of the invention is to produce a bituminous emulsion eflicient in impartmg high loadcarrying capacity to soils and other mineral matter in the presence of water and/or imparting resistance to absorption of water.

Still another purpose is to provide an economical stabilizing agent for bituminous emulsions which is resistant to deterioration by alkali, is effective to stabilize the emulsion against coalescence or :breakdown when mixed with electrolytes, aggregates, Portland cement and the like, and which is resistant to denaturization in the presence of aqueous'alkaline solutions at relatively v elevated temperatures.

An additional object comprises production of novel stabilizers for emulsions.

produce bituminous emulsions.

This invention in its preferred embodiment comprises the stabilization of pre-formed bituminous emulsions in which the reaction products of an alkaliwith the naturally occurring constituents 0f the bitumen are the sole primary emulsifying' agents. However, it is apparent that the use of other emulsifying agents or of suitable auxiliary primary emulsifying agents, in addition' to said reaction products, is within the scope of the even though stored at high temperatures such as 55 invention in .its broader aspect. For instance,

, bitumen in the added alkaline water.v

11. asvaeee high molecular weight naphthenic acids may be employed for emulsification as in the case of the previously mentioned asphalto enic acids. The alkali salts of such naphthenic acids formed in situ during emulsification or added separately comprise alternative emulsifying agents. Likewise, high molecular weight acids formed by partial oxidation of petroleum hydrocarbons by methods known in the art, or acids such as those contained in Montan wax when used as auxiliary primary emulsifiers, are regarded as within the broader scope of the invention. The alkali salts of these acids may be formed either separately or in situ during emulsification of the lbitumen. On the other hand, the presence of fatty acid soaps in the emulsion has an undesirable effect on the action of the stabilizing agents herein disclosed.. Pre-formed emulsions containing fatty acid soaps in small quantities can be stabilized by the method of this invention and are usable for certain purposes, but the stabilized emulsion usually has less desirable qualities than do emulsions substantially free of fatty acid soaps.

Illustrative methods of preparing bituminous emulsions suitable for stabilization according to this invention are disclosed in the patent to Montgomerie, No. 1,643,675, granted September 27, 1927, and in the patent to Braun, No. 1,737,491, granted November 26, 1929. The Montgomerie patent discloses emulsification by mixing melted bitumen directly with hot, dilute alkaline water. Braun forms a bituminous emulsion by adding molten bitumen and alkaline water to a preformed emulsion often referred to as a mother liquor, which facilitates emulsification of the Those skilled in the bituminous emulsion art recognize that alkaline water suitable for the above processes may be obtained by the addition of various alkaline materials and it is intended to include such alternative alkali, as well as other emulsifying agents such as those herein previously mentioned, within the scope of the invention and claims.

The stabilizing agents of this invention are particularly effective where caustic soda or caustic with the asphaltogenic acids in the bitumen to produce emulsification,

Bituminous emulsions prepared by the Montgomerie or Braun methods are commonly termed quick-breaking or quick-setting emulsions because of their tendency to break down or separate into agglomerated masses when diluted with water, contaminated with electrolytes or foreign matter, or when combined with aggregates or fibrous material or applied to surfaces in the customary methods of handling. Other emulsions partake of quick-breaking characteristics to a greater or lesser degree depending on the character and quantity of emulsifying agent employed and the method of manufacture. Various expedients have been adopted in an effort to impart slow-setting or mixing properties to such quick-breaking e'mulsions and thereby render them stable against coalescence in the presence of electrolytes and adaptable to uses where the ability to mix with other substances rather than quick-setting properties are desired.

The addition of quantities of certain stabilizing agents insuflicient in themselves to exert any substantial emulsifying action, but which by some unpredictable action effect stabilization of these emulsions has been utilized in the prior potash are the alkaline materials used to react art. Difficulties have been encountered with emulsions s0 stabilized, in some cases, because of the deleterious effects of even small quantities of certain stabilizing agents on the bitumen deposited from the emulsion and because of deterioration 0f the stabilizing agents after incorporation and their consequent loss of beneficial action.

Prior experience has shown that the suitability of unproven stabilizing agents for bituminous emulsions is, as a rule, unpredictable and that generalities are inapplicable in these highly empirical developments. As an example, various statements in the literature indicate that proteins as a class may be used as stabilizers for bituminous emulsions and that they may be substituted one for the other as substantial or full equivalents. As a matter of fact, such teachings are erroneous, at least insofar as production of practical emulsions suitable for commercial purposes is concerned.

Blood has been proposed as a stabilizing agent. Where liquid blood has heretofore been adopted, it has been regarded as absolutely essential that the blood be defibrinized, i. e., have the fibrinogen removed therefrom as fibrin by suitable known treatments, such as whipping with a bundle of wires, so that the blood will not coagulate. This defibrinization was thought necessary because fresh liquid blood coagulates to form a gel when allowed to stand in air or when contacted with extraneous agents, and there was no known way of utilizing such a coagulated semi-solid material as an emulsion stabilizer.

Contrary to the above prior knowledge and teaching of the art, this invention utilizes liquid blood as a stabilizer without defibrinization thereof. It has been discovered that a homogeneous liquid blood containing the coagulants fibrinogen' or fibrin, or both, naturally present in blood may be advantageously utilized as a stabilizer to give a bituminous emulsion having the desirable properties disclosed in this specification. Stabilization with homogeneous liquid blood containing said coasulants is particularly advantageous in that it avoids not only the time and expense necessitated by deflbrlnization but also avoids the loss of useful colloids normally present in the blood which are entrapped and removed during deflbrinization. Further, use of whole liquid blood rather then dried blood avoids treatment of the blood by heating to produce evaporation and the concomitant careful control heretofore essential to preclude substantial deteriorationof the protein bodies in the blood and consequent loss of stabilizing properties.

According to the process of this invention, the liquid blood containing coagulants must be sultably treated in order to render it adaptable for the stabilization of emulsions. Such treatments involve homogenization of the blood, preferably after coagulation, to disperse the fibrin substantially uniformly throughout the material, or theincorporation of suitable agents in the blood which inhibit gelling or coagulation by preventing conversion of the flbrinogen to fibrin and thereby maintain the blood in a homogeneous condition. 'It should be observed that the suitability and effectiveness of blood containing coagulants as a stabilizer for bituminous emulsions could not be predicted. It was not apparent that whole liquid blood could be treated to render it useful as an emulsion stabilizer because one might expect to encounter difliculties from gelling or coagulation. For example, blood alone, homogenized as taught herein, tends to collect on and plug sieves by reason of the presence of the coagulant fibrin, and one might anticipate that this same action would occur after addition to the bituminous emulsion with the result that the product would not pass a screen test specified for most commercial emulsions. Also, gelling of the completed emulsion could be expected from the potent gelling agent, blood. Likewise, one might anticipate thataddition of precipitants for the calcium ion would not be effective to prevent the normal gel-forming tendency of the fibrinogen after dilution and in the presence of the emulsifying agents for bituminous emulsionsthis particularly in view of the fact that emulsions often tend to form gels, even in the absence of the coagulating or gelling agents present in blood. r

Homogenization of coagulated blood may be effected for the purposes of this invention by passing the blood first through a centrifugal pump and then through a suitable type of homogenizer, such as a colloid mill or high speed centrifugal mixer. The invention is not limited to this particular method of homogenization, since other alternatives will readily occur to those skilled in the art. For example, one may simultaneously.

homogenize the blood and stabilize the emulsion by passing whole blood, either coagulated or uncoagulated, with the emulsion through a colloid mill.

After the blood is homogenized, it is not necessary to immediately incorporate the product in an emulsion,- since the homogenized liquid blood retains its fiuid characteristics, and when it contains suitable preservatives, may be stored, shipped or sold as a stabilizer for emulsions.

When the homogenized coagulant containing liquid blood is not to be utilized immediately by addition to emulsions, a preservative should be incorporated. Suitable preservatives are sodium arsenite, formalin solution (40% formaldehyde in water), phenol or phenolic compounds, and the like. For example, 0.2% by weight of formalin may be utilized. Also, 1 pint of kerosene per 55- gallon drum of blood or 1 pint of turpentineor 1 ounce of naphthalene flakes may be incorporated to render the product inedible if required by the Bureau of Animal Industry. When the blood is preserved in this manner, for most uses of the bituminous emulsion stabilized therewith, additional preservative will be found unnecessary. In some cases additional preservative, e. g., 0.1% of formalin, may be added to the completed emulsion.

As previously implied, an alternative method of treating the blood containing coagulants comprises the incorporation of precipitants for the calcium ion, either with or without homogenizing treatment. Suitable materials are sodium oxalate, potassium oxalate, sodium citrate, potassium citrate, sodium fluoride, or other salts, such as th sodium phosphate which react with the calcium ion to removethe same from the blood. Hirudin and heparin prevent conversion of fibrinogen to fibrin with consequent avoidance of coagulation and may be utihzed for this purpose. Where circumstances dictate avoidance of homogenization of the-blood, it may be collected in non-wettable containers, such as parafiin.

coated vessels, .to delay the clotting or coagulating action of the fibrinogen and promptly treated with an agent for preventing gelling, as above disclosed.

In stabilizing an emulsion according to this invention, suflicient of the homogeneous coagulant containing liquid blood should be incorporated to give at least 0.1% by weight of blood solids based on the weight of the completed emulsion. The most effective range seems to be from 0.3% to 1.0% by weight based on the completed emulsion. The blood may be added while the emulsion is still hot from the manufacturing operation. High temperatures of the emulsion at the time of stabilization do not destroy the stabilizing action of the blood. Addition of the stabilizer to an emulsion which may have cooled to atmospheric temperatures below approximately 100 F. is not precluded, particularly where it is found inconvenient to handle a hot emulsion during the incorporation of the blood therein, or any temperature between atmospheric and manufacturing temperatures may be adopted.

An alternative method of stabilization comprises subjecting the asphalt or other bituminous material to powerful shearing forces in the presence of an emulsifying agent such as the aqueous alkaline solution hereinbefore disclosed, to form a fine dispersion of the asphalt in water. When the asphalt or bituminous material is of the type which does not emulsify in water containing an alkali alone, the fine dispersion formed with the aqueous alkaline solutionis exceedingly unstable and coalesces promptly unless immediately stabilized. Such stabilization may be effected by the immediate incorporation of the homogeneous coagulant containing liquid blood herein disclosed. Asphalts which do not emulsify with water containing a metal hydroxide alone to give a stable quick-setting emulsion may be satisfactorily emulsified according to this method in a colloid mill. The mill applies the powerful shearing forces previously referred to when the molten asphalt and hot alkaline solution containing the alkali are added thereto. A

line dispersion of the asphalt is initially formed and may be immediately passed to a second emulsifying zone where the unstable emulsion is promptly stabilized with the blood before coalescence has occurred. When coagulated blood is used as a stabilizer, it may also be simultaneously homogenized in this second emulsifying zone but addition of a previously homogenized blood is preferred. Another method of effecting formation of a satisfactory emulsion is to apply the alkaline aqueous solution in the colloid mill and stabilize the asphalt emulsion as formed in the mill by simultaneously incorporating the homogeneous blood stabilizer. Further, the stabilizer may be added to the aqueous alkaline solution prior to emulsification in the c'olloid mill. When an auxiliary emulsifier such as a small quantity of liquid rosin oil or other saponifiable material is utilized to aid initial'formation of a quicksetting emulsion, the rosin oil may be introduced either into the colloid mill during emulsification or into the alkaline water prior to emulsification.

When preparing quick-setting emulsions of the.

Montgomerie or Braun type for stabilization according to this invention, an emulsion containing approximately 50% to 60% asphalt and 50% to 40% alkaline water is preferred. Water temperatures during emulsification may be maintained at to F., asphalt at 240 to 280 F., andthe mixture at 200 to 210- F., to yield a satisfactory emulsion. These temperatures are not critical; I for example, water temperature may be raised and asphalt temperature lowered to give the same resultant temperature in the mixture. The

eminent importance.

asphalt should be sufficiently hot to render it fluid in order that agitation and emulsification may be geneous liquid blood containing coagulants by the preferred method, the finished product has a pH of 115+. Emulsions reaching a pH of less than 9.0 usually show an appreciable deterioration and a'pH of 9.0 is regarded as the lowest safe limit of alkalinity for this preferred, type of emulsion.v

Where during long storage chemical reactions occur and the pH tends to drop below 9.0, alkali may be added to raise the alkalinity of the emulsion above the critical point. Theupper limit of pH concentration is, for the purposes of this invention, not criticalwithin the range wherein the preformed emulsionis satisfactory, i. e., stable against coalescence of the dispersed phase under storage conditions ordinarily encountered.

' stabilized emulsion is preferably neutralized to a point between pH 10 and pH 11. A suitable neutralizing agent is phosphoric acid, although other 1 weekly acid solutions may be used. This partially neutralized although stillalkaline emulsion has different physical characteristics from the unneutralized product. For example, it has a, more rapid rate of drying. The partially neutralized emulsion has greater resistance to heat deterioration, while the unneutralized emulsion is more resistant to freezing. Thus, th partially neutralized emulsion has particular utility where resistance to heat or increased drying rateis of presuitable quantities and when the emulsion is not to be utilized promptly, it is usually necessary to incorporate a preservative for the stabilizer to prevent deterioration by mold or bacterial action.

It should be understood that the invention in 1 its broader aspects is not limited to emulsions of pH greater than 9.0 as above described, since the invention is applicable to emulsions having various emulsifying agents and pH ranges.

To exemplify our invention in further detail the preparation, proportions and properties of emulsions utilizing this invention will now be described.

Emulsions were prepared by the Montgomerie process using a California asphalt. The emulsions were then stabilized with homogeneous liquid blood which had been allowed to coagulate and,subjected to homogenization prior to incorporation in .the emulsion. The blood stabilizer contained 0.2% formalin and 1 pint of kerosene per 55 gallons of the liquid blood. Table I gives the data on such emulsions with various percentages of the blood stabilizer.

Ade!

The unneutralized' emuly Table l Per cent stabilizer (dry I weight 0. 05 0. l 0. 25 0. 50 1. 00 Added water--per cent.. 4. 25 3.90 3. 20 1.90 0 Residue .do '57. 0 57. 2 57. 2. 57. 0 5 6. 8 I Dcmulsibility (0.02 N.

calcium chloride solu- .tion) (i5. 3 27. l 0 0 0 Demulsibility (0.10 N.

calcium chloride solution) 100 100 U 0 0 Viscosity (Saybolt Furol 10 77 F 47.9 51.4 63.4 72.5 79.8 Sic 0. 022 O. 018 0. 005 0. 003 0.002 pH (glass electrode) ll. 9 ll.8 11. 9 11.0 11.75 Cement miring test. Failed Failed l0.0 Passed Passed Drying 0.423 0. 485 0. 540 0.560 O. 555

To illustrate the use of precipitants for the calcium ion, the following data. are given. Emuls'ions designated A were stabilized with. liquid blood which had not been coagulated or defibrinnized and containing 55.7 grams of dry sodium oxalate to each 5 gallons and 0.5% kerosene In emulsion B liquid blood which had not been 00- agulated' or defibrinized and containing 111.1 g

' grams of dry sodium fluoride to each 5 gallons and containing 0.5% kerosene was utilized. The

data on'these emulsions is given in Table II.

Table II Per cent stabi- I 3o lizer 0.3 0.6 1.0 0.3 0.6 1.0

- Formalin I per cent 0.3 0.3 0.3 0.3 0.3 0.3 Residue I per ceut 58.2 58.0 57.2 p 58.4 g 57.7 57.1 Viscosity 50. 8 58. 0 57. 2 51. 4 64. 2 76. 8 Cementmixing I test Bgr. Passed Passed Passed Passed Passed Demulsibilityn. 0 0 0 0 0 Sieve; Trace Trace Trace Trace -Trace Trace pH 11.8 11.8 11.8 ll. 6+ 11.6+ 11.8 Drying; 0. 414 0.654 0.770 0.433 0.613 0.760

-Many variations in composition and uses are 40 within the scope of the invention in its generic aspect. For instance, the bituminous material dispersed may be of eitherhigh or low melting point, solid, semi-solid or semi-liquid, depending on the properties desired of the deposited mate- Hardness, ductility and fusibility of the bitumen may be altered and controlled by the use of blending agents.

Fibrous fillers such as asbestos, or organic fibers such as cotton and mineral pigment fillers such as ground petroleum coke, iron oxide, chromium 0X- ide, or limestone dust may be added singly or in combination to the completed emulsion when desired. Such fillers and pigments may be mixed with the homogeneous blood stabilizer prior to incorporation in the emulsion, but are preferably incorporated separately therefrom and after it has been added to stabilize the emulsion.

A typical example of the proportions in which these materials may be satisfactorily mixed is as Water in addition to that present in the original emulsion 24 In organic cementitious materials other than the Portland cement hereinbefore disclosed may also be mixed withv the stabilized emulsion. Hy-

dratedlime and gypsum comprise two such cementitious materials.-

The emulsion is adapted for use as a coating or waterproofing composition for metal, wood, or

concrete structures; for impregnation ofwoven aszacas fabrics, felted fabrics and paper; for pipe sealing 7 compounds: ior electrical insulation compounds;

for mixing with mineral aggregates in p l and when'wet.

Bythe term fhomogeneous coagulant containing liquid blood," wherever used herein, it is in-- tended to designate liquid blood containing fibrin or fibrinogen which would normally cause the blood product to be a semi-solid or to set up as a semi-solid clot or gel, but in which gel or clot is not present by reason of the treatments disclosed in this specification. I

The term "coagulant" is utilized throu hout the specification and claims to designate fibrinogen or fibrin.

Liquefied coagulated blood," wherever used sion which comprises forming a dispersion of bitumen in water and stabilizing said dispersion with homogeneous non-coagulable liquid blood iormedby homogenization of undefibrinized coagulated blood.

.5. A process of preparing an asphalt emulsion which comprises forming a quick breaking dis-' persion of asphalt in alkaline water and stabilizing said dispersion by incorporating therein homogeneous non-coagulable liquid blood formed by homogenization of undefibrlnized coagulated blood in an amount suificient to yield from about 0.1% to about 1% by weight of blood solids based on the complete emulsion.

.8. A process of emulsifying a bitumen which is difilculty emulsifiable in water containing an altrail as the sole emulsifying agent said process comprising subjecting the bitumen to shearing herein, designates liquid blood which has been allowed at least partially to coagulate and then subjected to a homogenizing treatment.

'Although preferred embodiments of the inven. tion have been'described in detail, it is to be understood that the invention is not limited thereto but comprehends all the variations and modifications within the scope of the appended claims.

We claim:

l. A bituminous emulsion comprising bitumen, water, an emulsifying agent and a stabilizer consisting essentially of homogeneous non-coagulable liquid blood formed by homogenization of undefibrinized coagulated blood.

2.' A bituminous emulsion comprising bitumen, water, an alkaline aqueous phase having a on greater than 9.0. and a stabiliz'erconsisting essentially oi homogeneous non-coa ulable liquid blood on the weight oithe complete emulsion.

-. 3. An aqueous bituminous emulsion stabilized by homogeneous non-coaaulable liquid blood formed by the homogenimtlon 0t u'ndefibrinized coagulatedbloodsaidbloodbeingpresentinan" amount of notiessthanui'lb by weight or blood soiidsbasedonthefinishodemulsiom' h p 4. A process of preparing a bituminous emulforces in the presence of an aqueous alkaline solution to form a dispersion of the bitumen in the alkaline water which would normally quickly coalesce, and immediately stabilizing said dispersion with a -small amount of homogeneous non-coagulable' liquid blood formed by homogenization of undefibrinized coagulated blood.

s 7. A process of preparing a stabilizer for bituminous emulsions which comprises coagulating whole blood, homogenizing said coagulated product to produce a liquefied coagulated blood, and stabilizing said liquefied coagulated blood against deterioration by incorporating a preservative against putretaction.

- 8. A process or preparing a bituminous emulsion which comprises forming a dispersion or bitumin in water and stabilizing said dispersion with homogeneous liquid blood which contains a coagulant selected from the group consisting of fibrinogen and fibrin, said coagulant being in a non-clotting state but present in an amount normally suflicientto produce clotting of said liquid blood.

a 9. The emulsion of claim 2, wherein saidbitumen is an asphalt and said bituminous emulsion is an emulsion of the oil-in-water type,

10. The emulsion of claim 8, wherein said bituminous emulsion is an asphalt emulsion of the oilin-water typ 4 'WALTER D.- BUCKIEY..

EDWIN P. BLY. 

